U.S. patent application number 10/585605 was filed with the patent office on 2008-10-16 for printing on comestible products.
Invention is credited to Stan Holtom, Fergal Keohane, John R. Russell, James F Woodhouse, Angela Wright.
Application Number | 20080254172 10/585605 |
Document ID | / |
Family ID | 39884532 |
Filed Date | 2008-10-16 |
United States Patent
Application |
20080254172 |
Kind Code |
A1 |
Woodhouse; James F ; et
al. |
October 16, 2008 |
Printing on Comestible Products
Abstract
A method for applying a color image to a non-planar comestible
may include applying a color image onto a substantially planar
carrier and deforming the carrier to form a non-planar relief mold
of a three-dimensional image, including deforming the color image
whereby the deformed color image is proportionate relative to,
i.e., is in register with, the three-dimensional image. A
comestible material, e.g., chocolate or a gelatinous edible
composition, may be deposited into the relief mold to substantially
overlie the color image. The comestible material may be removed
from the relief mold, with the color image applied thereto. In one
implementation, the color image may be applied to the substantially
planar carrier by screen printing one or more colors forming the
color image onto the carrier using an edible ink composition.
Inventors: |
Woodhouse; James F; (Tyne
& Wear, GB) ; Holtom; Stan; (Northumberland,
GB) ; Russell; John R.; (Northumberland, GB) ;
Wright; Angela; (Northumberland, GB) ; Keohane;
Fergal; (Northumberland, GB) |
Correspondence
Address: |
FISH & RICHARDSON P.C.
PO BOX 1022
MINNEAPOLIS
MN
55440-1022
US
|
Family ID: |
39884532 |
Appl. No.: |
10/585605 |
Filed: |
January 14, 2005 |
PCT Filed: |
January 14, 2005 |
PCT NO: |
PCT/US05/01241 |
371 Date: |
March 13, 2008 |
Current U.S.
Class: |
426/231 ;
426/383; 426/573; 426/574 |
Current CPC
Class: |
A21D 13/47 20170101;
A23P 2020/253 20160801; A23G 3/50 20130101; A23L 5/42 20160801;
A23G 3/0097 20130101; A23G 3/0027 20130101; A23G 3/28 20130101;
A23G 3/343 20130101; A23L 29/284 20160801 |
Class at
Publication: |
426/231 ;
426/383; 426/573; 426/574 |
International
Class: |
G01N 33/02 20060101
G01N033/02; A23L 1/00 20060101 A23L001/00; A23L 1/05 20060101
A23L001/05; A23L 1/056 20060101 A23L001/056 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 15, 2004 |
US |
10758236 |
Claims
1. A method for printing an image on a gelatinous edible
composition, the method comprising: applying an image using an
edible ink composition onto a substantially planar carrier, the
image being disproportionate relative to an original version of the
image; forming a three dimensional impression in the carrier to
form a non-planar relief mold for a gelatinous edible composition,
such that the three dimensional impression formed in the carrier
corresponds to a three dimensional representation of the original
version of the image and wherein the image applied to the carrier
is in register with the three dimensional representation;
depositing a gelatinous edible composition into the relief mold to
substantially overlie the image; and removing the gelatinous edible
composition with the image applied thereto from the relief
mold.
2. The method of claim 1, wherein a boundary of the image applied
to the carrier is in register with a boundary of the three
dimensional impression formed in the carrier.
3. The method of claim 1, wherein forming a three dimensional
impression in the carrier to form a non-planar relief mold
comprises: creating a vacuum between a surface of a three
dimensional non-planar model corresponding to a three dimensional
representation of the original version of the image and a carrier
and vacuum forming the carrier to the surface of the model.
4. The method of claim 3, wherein the surface of the model is
coated with a heat resistant, non-stick material.
5. The method of claim 1, wherein the image comprises a multi-color
image.
6. The method of claim 1, wherein the carrier comprises a
thermoplastic sheet.
7. The method of claim 1, wherein applying an image onto a
substantially planar carrier includes: screen printing one or more
colors comprising the image onto the carrier using one or more
colors of an edible ink composition.
8. The method of claim 7, wherein the edible ink composition
comprises: a) one or more viscosity controllers; b) one or more
film forming compounds; c) one or more emulsifiers; and d) one or
more food grade colorants.
9. The method of claim 8, wherein the edible ink composition
further comprises one or more plasticizers.
10. The method of claim 8, wherein the edible ink composition
further comprises one or more humectants.
11. The method of claim 8, wherein the edible ink composition
further comprises water.
12. The method of claim 8, wherein the edible ink composition is an
aqueous edible ink composition comprising: a) one or more viscosity
controllers at about 65% to about 80% by weight of said aqueous
edible ink composition; b) one or more film forming compounds at
about 0.6% to about 4% by weight of said aqueous edible ink
composition; and c) one or more emulsifiers at about 1% to about
12% by weight of said aqueous edible ink composition.
13. The method of claim 12, wherein the aqueous edible ink
composition further comprises a plasticizer at about 0.03% to about
0.4% by weight.
14. The method of claim 12, wherein the aqueous edible ink
composition further comprises water at about 13% to about 25% by
weight.
15. The method of claim 12, wherein the aqueous edible ink
composition further comprises a powdered ink.
16. The method of claim 1, wherein said depositing of said
gelatinous edible composition in said relief mold occurs at a
temperature of from about 40.degree. C. to about 80.degree. C.
17. The method of claim 16, wherein said temperature is from about
50.degree. C. to about 75.degree. C.
18. The method of claim 17, wherein said temperature is from about
60.degree. C. to about 70.degree. C.
19. The method of claim 16, further comprising exposing said
deposited gelatinous edible composition in said relief mold to a
temperature of from about 4.degree. C. to about 10.degree. C. in
order to form a skin on said deposited gelatinous edible
composition.
20. The method of claim 19, wherein said temperature is about
5.degree. C.
21. The method of claim 19, wherein said exposing occurs in a
cooling tunnel.
22. The method of claim 19, further comprising allowing said
deposited gelatinous edible composition in said relief mold to set
for a period of about 1 to about 5 hours at a temperature of from
about 1.degree. C. to about 5.degree. C.
23. The method of claim 22, wherein said period is about 2 to about
4 hours.
24. The method of claim 22, further comprising conditioning said
deposited gelatinous edible composition in said relief mold.
25. The method of claim 24, wherein said conditioning occurs at a
temperature of from about 19.degree. C. to about 24.degree. C.
26. The method of claim 25, wherein said conditioning occurs at a
temperature of from about 20.degree. C. to about 22.degree. C.
27. The method of claim 24, wherein said conditioning Occurs for a
period of from about 14 to about 75 hours.
28. The method of claim 27, wherein said period is from about 18 to
about 24 hours.
29. The method of claim 27, wherein said period is from about 20 to
about 72 hours.
30. The method of claim 24, wherein said conditioned gelatinous
edible composition exhibits a moisture content of from about 15% to
about 22%.
31. The method of claim 30, wherein said conditioned gelatinous
edible composition exhibits a moisture content of from about 17% to
about 20%.
32. A method for printing an image on a gelatinous edible
composition, comprising: a) creating a three-dimensional model
based on an original two-dimensional artwork, the original
two-dimensional artwork including an outline and one or more
colored regions; b) printing an outline of the original
two-dimensional artwork onto a substantially planar carrier; c)
vacuum forming the printed carrier to the three-dimensional model
thereby forming a three-dimensional impression in the printed
carrier at a location coinciding with the outline printed on the
carrier thereby deforming the outline, where the three-dimensional
impression formed in the carrier is a three dimensional
representation of the original two-dimensional artwork; d)
measuring misalignment of the deformed outline to the
three-dimensional impression and creating an adjusted
two-dimensional artwork based on the original two-dimensional
artwork and the measurements, the adjusted two-dimensional artwork
including an adjusted outline; f) repeating steps b through d where
the adjusted outline is printed onto a carrier in step b, until an
outline of an adjusted two dimensional artwork printed on a carrier
substantially aligns with a three-dimensional impression formed in
the carrier, where said adjusted two-dimensional artwork thereby
forms a final two-dimensional artwork; g) printing a colored image
corresponding to the final two-dimensional artwork onto a carrier;
h) vacuum forming the printed carrier to the three-dimensional
model thereby creating a three-dimensional impression in the
printed carrier that aligns to the colored image, where the
three-dimensional impression forms a relief mold; and i) filling
the relief mold with a gelatinous edible composition.
33. The method of claim 32, further comprising: removing the
gelatinous edible composition with the colored image adhered
thereto from the relief mold.
34. The method of claim 32, wherein the carrier is a thermoplastic
sheet.
35. The method of claim 1 or claim 32, wherein said gelatinous
edible composition is a nougat or gummi-type gelatinous edible
composition.
36. A gummi-type gelatinous edible composition comprising one or
more of each of the following: a sweetener, a gelling agent, and a
shortening agent.
37. The gummi-type gelatinous edible composition of claim 36,
further comprising water.
38. The gummi-type gelatinous edible composition of claim 37,
wherein said water is included from about 10% to about 35% by
weight of the final composition.
39. The gummi-type gelatinous edible composition of claim 37,
wherein said one or more sweeteners are included at a percentage by
weight of the final composition of about 30% to about 75%.
40. The gummi-type gelatinous edible composition of claim 39
wherein said one or more sweeteners are selected from the group
consisting of: cane sugar, granulated sugar, a sugar syrup, and a
low calorie syrup.
41. The gummi-type gelatinous edible composition of claim 36,
wherein said one or more gelling agents are selected from fish,
bovine, and poultry gelatin.
42. The gummi-type gelatinous edible composition of claim 36,
wherein said one or more gelling agents are included in an amount
of from about 3% to about 10% by weight of the final
composition.
43. The gummi-type gelatinous edible composition of claim 36,
wherein said one or more shortening agents are included in an
amount of from about 0% to about 5% by weight of the final
composition.
44. The gummi-type gelatinous edible composition of claim 43
wherein said one or more shortening agents is selected from the
group consisting of unrefined, refined, modified and unmodified
starches.
45. The gummi-type gelatinous edible composition of claim 44,
wherein said one or more shortening agents is selected from the
group consisting of wheat starch, maize starch, potato starch, and
tapioca starch.
46. A method for preparing a gummi-type gelatinous edible
composition comprising: a) hydrating a gelling agent; b) combining
one or more sweeteners to form a sweetener solution; c) heating
said sweetener solution to a temperature from about 110.degree. C.
to about 120.degree. C. and then cooling said heated sweetener
solution to a temperature from about 90.degree. C. to about
100.degree. C.; and d) mixing said gelling agent solution with said
cooled sweetener solution to form a gummi-type gelatinous edible
composition.
47. The method of claim 46, further comprising: e) depositing said
gummi-type gelatinous edible composition from step d) at a
temperature of from about 40.degree. C. to about 80.degree. C.
within about 30 minutes into a printed relief mold.
48. The method of claim 47, further comprising exposing said
deposited gelatinous edible composition to a temperature of from
about 4.degree. C. to about 10.degree. C. for a period from about
10 to about 20 minutes in order to form a skin on said deposited
gelatinous edible composition.
49. The method of claim 48, further comprising allowing said
deposited gelatinous edible composition to set for a period of
about 1 to about 5 hours at a temperature of from about 1.degree.
C. to about 5.degree. C.
50. The method of claim 49, further comprising conditioning said
deposited gelatinous edible composition at a temperature of from
about 19.degree. C. to about 24.degree. C. for a period of from
about 14 to about 75 hours.
51. A nougat-type gelatinous edible composition comprising one or
more of each of the following: a sweetener and an aerating
agent.
52. The nougat-type gelatinous edible composition of claim 51
further comprising water from about 4% to about 35% by weight of
the final composition.
53. The nougat-type gelatinous edible composition of claim 51,
wherein said one or more sweeteners can be included at a percentage
by weight of the final composition of about 60% to about 95%.
54. The nougat-type gelatinous edible composition of claim 53,
wherein said one or more sweeteners are selected from the group
consisting of: cane sugar, granulated sugar, icing sugar, a sugar
syrup, and a low calorie syrup.
55. The nougat-type gelatinous edible composition of claim 54,
wherein said one or more aerating agents are included at a
percentage from about 0.05% to about 1.5% by weight of the final
composition.
56. The nougat-type gelatinous edible composition of claim 55,
wherein said aerating agent is hydrolysed wheat gluten.
57. A method for preparing a nougat-type gelatinous edible
composition comprising: a) mixing one or more aerating agents with
one or more sweeteners to form a stiff foam; b) heating one or more
sweeteners at a temperature from about 125.degree. C. to about
140.degree. C.; and c) combining the stiff foam of a) with the
heated sweetener of b) to form a gelatinous edible composition.
58. The method of claim 57 further comprising: depositing said
gelatinous edible composition from step c) at a temperature of from
about 40.degree. C. to about 80.degree. C. within about 30 minutes
into a printed relief mold.
59. The method of claim 58, further comprising: exposing said
deposited gelatinous edible composition to a temperature of from
about 4.degree. C. to about 10.degree. C. for a period of about 10
to about 20 minutes in order to form a skin on said deposited
gelatinous edible composition.
60. The method of claim 59, further comprising allowing said
deposited gelatinous edible composition to set for a period of
about 1 to about 5 hours at a temperature of from about 1.degree.
C. to about 5.degree. C.
61. The method of claim 60, further comprising conditioning said
deposited gelatinous edible composition at a temperature of from
about 19.degree. C. to about 24.degree. C. for a period of from
about 14 to about 75 hours.
62. A method for creating a relief mold, the method comprising:
applying an image using an edible ink composition onto a
substantially planar carrier, the image being disproportionate
relative to an original version of the image; and forming a three
dimensional impression in the carrier to form a non-planar relief
mold for a comestible material, such that the three dimensional
impression formed in the carrier corresponds to a three dimensional
representation of the original version of the image and wherein the
image applied to the carrier is in register with the three
dimensional representation.
63. The method of claim 62, wherein a boundary of the image applied
to the carrier is in register with a boundary of the three
dimensional impression formed in the carrier.
64. The method of claim 62, wherein forming a three dimensional
impression in the carrier to form a non-planar relief mold
comprises: creating a vacuum between a surface of a three
dimensional non-planar model corresponding to a three dimensional
representation of the original version of the image and a carrier
and vacuum forming the carrier to the surface of the model.
65. The method of claim 64, wherein the surface of the model is
coated with a heat resistant, non-stick material.
66. The method of claim 62, further comprising: depositing a
comestible material into the relief mold to substantially overlie
the image; and removing the comestible material with the image
applied thereto from the relief mold.
67. The method of claim 62, wherein the image comprises a
multi-color image.
68. The method of claim 62, wherein the carrier comprises a
thermoplastic sheet.
69. The method of claim 62, wherein applying an image onto a
substantially planar carrier includes: screen printing one or more
colors comprising the image onto the carrier using one or more
colors of the edible ink composition.
70. The method of claim 69, wherein the edible ink composition
comprises: a) one or more viscosity controllers; b) one or more
film forming compounds; c) one or more emulsifiers; and d) one or
more food grade colorants.
71. The method of claim 70, wherein the edible ink composition
further comprises one or more plasticizers.
72. The method of claim 70, wherein the edible ink composition
further comprises one or more humectants.
73. The method of claim 70, wherein the edible ink composition
further comprises water.
74. The method of claim 70, wherein the edible ink composition is
an aqueous edible ink composition comprising: a) one or more
viscosity controllers at about 65% to about 80% by weight of said
aqueous edible ink composition; b) one or more film forming
compounds at about 0.6% to about 4% by weight of said aqueous
edible ink composition; and c) one or more emulsifiers at about 1%
to about 12% by weight of said aqueous edible ink composition.
75. The method of claim 74, wherein the aqueous edible ink
composition further comprises a plasticizer at about 0.03% to about
0.4% by weight.
76. The method of claim 74, wherein the aqueous edible ink
composition further comprises water at about 13% to about 25% by
weight.
77. The method of claim 74, wherein the aqueous edible ink
composition further comprises a powdered ink.
78. A relief mold for creating a three-dimensional comestible
product, the relief mold comprising: a three dimensional impression
formed in a carrier, the three dimensional impression corresponding
to a three dimensional representation of a two dimensional image;
and an image applied in an edible ink composition to an interior
surface of the three dimensional impression, the image being a
disproportionate version of the two dimensional image, such that
the disproportionate image is in register with the three
dimensional impression formed in the carrier.
79. The relief mold of claim 78, wherein the edible ink composition
is deposited onto the carrier by a screen printing process using
one or more colors of edible ink composition.
80. The relief mold of claim 78, wherein the image applied to an
interior of the impression comprises a multi-color image.
81. The relief mold of claim 78, wherein the carrier comprises a
thermoplastic sheet.
82. The relief mold of claim 78, wherein the edible ink composition
comprises: a) one or more viscosity controllers; b) one or more
film forming compounds; c) one or more emulsifiers; and d) one or
more food grade colorants.
83. The relief mold of claim 78, wherein the edible ink composition
comprises: a) about 73.3% by weight fondant icing sugar; b) about
0.8% by weight hydroxypropylmethylcellulose; c) about 2.9% by
weight POLYSORBATE 60 and about 5.9% by weight lecithin; d) about
0.06% propylene glycol; and e) about 16.8% water.
84. An edible ink composition comprising: a) one or more viscosity
controllers; b) one or more film forming compounds; c) one or more
emulsifiers; and d) one or more food grade colorants.
85. The edible ink composition of claim 84, wherein the edible ink
composition further comprises one or more plasticizers.
86. The edible ink composition of claim 84, wherein the edible ink
composition further comprises one or more humectants.
87. The edible ink composition of claim 84, wherein the edible ink
composition comprises water.
88. The edible ink composition of claim 84, wherein the edible ink
composition is an aqueous edible ink composition comprising: a) one
or more viscosity controllers at about 65% to about 80% by weight
of the aqueous edible ink composition; b) one or more film forming
compounds at about 0.6% to about 4% by weight of the aqueous edible
ink composition; and c) one or more emulsifiers at about 1% to
about 12% by weight of the aqueous edible ink composition.
89. The edible ink composition of claim 88, wherein the aqueous
edible ink composition further comprises a plasticizer at about
0.03% to about 0.4% by weight.
90. The edible ink composition of claim 88, wherein the aqueous
edible ink composition comprises water at about 13% to about 25% by
weight.
91. The edible ink composition of claim 88, wherein the aqueous
edible ink composition comprises a powdered ink.
92. The edible ink composition of claim 90, wherein the edible ink
composition is an aqueous edible ink composition comprising: a) one
or more viscosity controllers at about 73% to about 75% by weight
of the aqueous edible ink composition; b) one or more film forming
compounds at about 0.5% to about 1.4% by weight of the aqueous
edible ink composition; c) one or more emulsifiers at about 5% to
about 12% by weight of the aqueous edible ink composition; d) one
or more plasticizers at about 0.03% to about 0.09% by weight of the
aqueous edible ink composition; and e) water at about 12% to about
20% by weight of the aqueous edible ink composition.
93. The edible ink composition of claim 92, wherein the one or more
viscosity controllers is fondant icing sugar; wherein the one or
more film forming compounds is hydroxypropylmethylcellulose;
wherein the one or more emulsifiers are lecithin and POLYSORBATE
60; and wherein the one or more plasticizers is propylene
glycol.
94. The edible ink composition of claim 93, comprising: a) about
73.3% by weight fondant icing sugar; b) about 0.8% by weight
hydroxypropylmethylcellulose; c) about 2.9% by weight POLYSORBATE
60 and about 5.9% by weight lecithin; d) about 0.06% by weight
propylene glycol; and e) about 16.8% by weight water.
95. A method for creating a relief mold for a comestible product,
comprising: a) creating a three-dimensional model based on an
original two-dimensional artwork, the original two-dimensional
artwork including an outline and one or more colored regions; b)
printing an outline of the original two-dimensional artwork onto a
substantially planar carrier; c) vacuum forming the printed carrier
to the three-dimensional model thereby forming a three-dimensional
impression in the printed carrier at a location coinciding with the
outline printed on the carrier thereby deforming the outline, where
the three-dimensional impression formed in the carrier is a three
dimensional representation of the original two-dimensional artwork;
d) measuring misalignment of the deformed outline to the
three-dimensional impression and creating an adjusted
two-dimensional artwork based on the original two-dimensional
artwork and the measurements, the adjusted two-dimensional artwork
including an adjusted outline; f) repeating steps b through d where
the adjusted outline is printed onto a carrier in step b, until an
outline of an adjusted two dimensional artwork printed on a carrier
substantially aligns with a three-dimensional impression formed in
the carrier, where said adjusted two-dimensional artwork thereby
forms a final two-dimensional artwork; g) printing a colored image
corresponding to the final two-dimensional artwork onto a carrier;
and h) vacuum forming the printed carrier to the three-dimensional
model thereby creating a three-dimensional impression in the
printed carrier that aligns to the colored image, where the
three-dimensional impression forms a relief mold.
96. The method of claim 95, further comprising: filling the relief
mold with a comestible material.
97. The method of claim 96, further comprising: removing the
comestible material with the colored image adhered thereto from the
relief mold.
98. The method of claim 95, wherein the carrier is a thermoplastic
sheet.
99. The method of claim 95, wherein printing a colored image onto a
carrier comprises: screen printing a colored image onto a carrier
using an edible ink composition.
100. The method of claim 99, wherein the edible ink composition
comprises: a) one or more viscosity controllers; b) one or more
film forming compounds; c) one or more emulsifiers; and d) one or
more food grade colorants.
101. The method of claim 100, wherein the edible ink composition
comprises: a) about 73.3% by weight fondant icing sugar; b) about
0.8% by weight hydroxypropylmethylcellulose; c) about 2.9% by
weight POLYSORBATE 60 and about 5.9% by weight lecithin; d) about
0.06% propylene glycol; and e) about 16.8% water.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. application Ser.
No. 10/759,236, filed Jan. 15, 2004, incorporated herein by
reference in its entirety.
TECHNICAL FIELD
[0002] This invention relates to techniques and compositions for
applying a decorative image to a comestible product, including
gelatinous comestible products.
BACKGROUND
[0003] Decorative images are frequently applied to confections and
food articles (i.e., comestible products), such as cakes, pastries,
ice cream, and baked goods. Frequently, decorative images are borne
on an edible substrate that is transferred to a surface of a food
article to be decorated. The edible substrates are often thin,
fragile layers of starch-based edible material. Such materials
facilitate transfer of the decorative image to the surface of the
food article without detracting from the texture or appearance of
the original food article. Preferably, the edible substrates may be
relatively durable so as to withstand the printing and transferring
processes.
[0004] Edible substrates may be deposited onto a releasable backing
paper or film to provide support throughout the printing process
and to facilitate handling of the edible substrate. After the
edible substrate is properly transferred to the food article, the
backing paper may be peeled away to show the decorative image on
the surface of the food article.
[0005] Edible substrates can be formed by depositing an edible
formulation on a backing paper using "screen printing" process. In
such processes, a screen fixture is positioned over the surface of
the backing paper and the edible material is manually forced
through a screen mesh using a squeegee or other similar device. The
screen printing process can be used to apply a decorative image to
a planar substrate for transfer to a planar target surface, such as
the flat surface of a cake.
[0006] Applying a decorative image to a non-planar (i.e.,
three-dimensional) target surface is typically more laborious and
time-consuming. Transferring a decorative image from release layer
(i.e., a 2D surface) onto a non-planar surface (i.e., a 3D surface)
can result in skewing or distortion of the decorative image, for
example, due to raised areas on the non-planar surface distorting
the originally 2D decorative image.
[0007] Accordingly, conventional techniques for applying a
decorative image to a non-planar surface include hand painting a
multi-colored image onto a relief mold surface using a pre-tempered
colored chocolate, and thereafter filling the mold with a
comestible material, such as chocolate, and, upon cooling,
demolding the chocolate with the multi-colored image applied. The
hand-painting technique is not conducive to mass production, due to
the time and expense involved.
SUMMARY
[0008] In various implementations, a method for applying a color
image to a non-planar comestible may include applying a
disproportionate color image onto a substantially planar carrier
and deforming the carrier to form a non-planar relief mold of a
three-dimensional image, whereby the deformed color image is
proportionate relative to the three-dimensional image. A comestible
material, such as chocolate or a gelatinous composition, may be
deposited into the relief mold to substantially overlie the color
image. The comestible material may be removed from the relief mold,
with the color image applied thereto. In one implementation, the
disproportionate color image may be applied to the substantially
planar carrier by screen printing one or more colors forming the
color image onto the carrier using an edible ink composition.
[0009] A gelatinous edible composition can be a nougat or
gummi-type gelatinous edible composition. A gummi-type gelatinous
edible composition can include one or more of the following: a
sweetener, a gelling agent, and/or a shortening agent. A
nougat-type gelatinous edible composition can include one or more
of each of the following: a sweetener and an aerating agent. A
gummi-type and nougat-type gelatinous edible composition can also
include water. Gelatinous edible compositions are generally
prepared at an elevated temperature for deposition into printed
relief molds, and then cooled and/or set and conditioned prior to
removal from the mold.
[0010] Edible ink compositions can include one or more of each of
the following: a viscosity controller, a film forming compound, an
emulsifier, and a food grade colorant. Optional ingredients include
one or more plasticizers or humectants. Edible ink compositions are
generally prepared as aqueous solutions, e.g., for application to a
carrier.
[0011] The details of one or more embodiments of the invention are
set forth in the accompanying drawings and the description below.
Other features, objects, and advantages of the invention will be
apparent from the description and drawings, and from the
claims.
DESCRIPTION OF DRAWINGS
[0012] FIG. 1A is a flowchart showing a process for creating a 3D
model.
[0013] FIGS. 1B and 1C are flowcharts showing a process for
applying a color image to a 3D comestible product.
[0014] FIG. 2 shows a 2D artwork representing a 3D decorative
image.
[0015] FIG. 3A shows an outline of an image printed onto the
surface of a substrate.
[0016] FIG. 3B show a 3D model affixed to the surface of the
substrate of FIG. 3A.
[0017] FIG. 4A shows a carrier aligned in a screen printing
machine.
[0018] FIG. 4B shows the carrier of FIG. 4A with a mirror image of
the artwork of FIG. 2 printed thereon.
[0019] FIG. 5 shows the carrier of FIG. 4B aligned in a vacuum
forming machine.
[0020] FIG. 6A shows the carrier of FIG. 4B impressed with the 3D
model of FIG. 3B.
[0021] FIG. 6B shows the reverse side of the carrier of FIG.
6A.
[0022] FIG. 7A shows a disproportionate version of the 2D artwork
of FIG. 2.
[0023] FIG. 7B shows the disproportionate 2D artwork of FIG. 7A
overlaying the 2D artwork of FIG. 2.
[0024] FIG. 8 shows a colored, disproportionate 2D artwork.
[0025] FIG. 9 shows a 3D comestible product adorning a bakery
item.
[0026] Like reference symbols in the various drawings indicate like
elements.
DETAILED DESCRIPTION
[0027] A technique for applying a decorative image to a
three-dimensional surface of a comestible product may include
applying a disproportionate image to a substantially planar carrier
and deforming the carrier into a three-dimensional relief mold,
such that upon being deformed, the decorative image is
proportionate to (i.e., aligns with) the three-dimensional (3D)
surface. The deformed decorative image can then be applied to a
three-dimensional target surface. The end product may be a
comestible product, for example, a chocolate figurine, a gelatinous
composition such as a gummi or nougat, or a cake decoration, having
at least one substantially non-planar surface, with a decorative
image of one or more colors applied to the non-planar surface of
the comestible product. For example, an edible gelatinous figurine
can be shaped as a popular cartoon character and a
three-dimensional image depicting the character can be applied to a
surface of the figurine.
[0028] An iterative process described below can be used to create
an image that is suitably disproportionate to an original 2D
artwork, such that when applied to a carrier and deformed into a 3D
relief mold, the image aligns with the corresponding 3D impression
formed in the carrier (i.e., the relief mold). Referring to FIG.
1A, a process 100 for creating a 3D model representative of a
comestible product to which a multi-colored decorative image is to
be applied is shown.
[0029] In a first step, a two-dimensional (2D) artwork is designed
illustrating a two-dimensional representation of the
three-dimensional decorative image to be applied to the
three-dimensional surface of the comestible product (step 102). For
example, referring to FIG. 2, a 2D artwork 200 of an image of a
cartoon man (the "Cartoon Man") is shown. A 3D temporary model of
the 2D artwork, i.e., a 3D Cartoon Man, is prepared based on the 2D
artwork (step 104). The temporary model may be hand sculpted from a
pliable material that can be hardened, such as plasticine or
modeling wax. Alternatively, the temporary model can be machined,
for example, using a CNC (computer numerical control) machine or
pantograph, and using a metal or plastic material.
[0030] A 3D temporary relief mold is created from the temporary
model, for example, by pouring a liquid, silicon rubber over the
temporary model and allowing the rubber to harden (step 106). The
rubber can then be separated from the temporary model, thereby
forming the 3D temporary relief mold. A food grade material that
can be used to form a solid, more durable permanent model, such as
resin, brass, aluminum or stainless steel, is poured in a liquid
form into the temporary relief mold (step 108). The material is
allowed to solidify and is removed from the temporary relief mold,
resulting in a permanent model representative of the comestible
product to which a multi-colored decorative image is to be applied
(step 110).
[0031] FIG. 1B is a flowchart showing a process 111 for creating an
adjusted 2D artwork that is suitably disproportionate to the
original 2D artwork 200, such that when applied to a carrier and
deformed into a 3D relief mold, the image represented by the
adjusted 2D artwork aligns with the corresponding 3D impression
formed in the carrier (i.e., the relief mold). Referring to FIG.
3B, in a first step, the permanent model 310 (which can be formed
as per FIG. 1A) is affixed to a substrate 305 that will be used
during a vacuum forming process. Optionally, before affixing the
permanent model to the substrate, an outline 300 of the decorative
image (i.e., a black outline without any colored regions) can be
applied to the substrate 305, as shown in FIG. 3A, and the
permanent model 310 then aligned to the outline 300 and mounted
onto the substrate 305. This step can be particularly useful for
commercial mass production of a comestible product, when multiple
permanent models may be created and affixed to a single substrate,
such that multiple relief molds can be simultaneously created. In
such an application, printing corresponding multiple outlines of
the image onto the substrate before affixing the multiple permanent
models facilitates a later step of align a carrier to the
models.
[0032] The permanent model 310 can be affixed to the substrate 305
using an adhesive, screws or other convenient means. The substrate
305 can be formed from a perforated stainless steel, for example,
such that during a vacuum forming process air can be extracted
through the perforations. Optionally, holes can be drilled through
the permanent model 310, which holes align with holes or
perforations in the substrate 305, such that during a vacuum
forming process air can be extracted through the holes, which can
be particularly useful in detailed regions of the permanent model
310.
[0033] The outline 300 can be applied to the substrate 305 using
any convenient printing technique, for example, screen printing.
The original 2D artwork 200 (FIG. 2) can be used to prepare a
screen, and using conventional screen printing techniques, the
outline 300 is printed onto the substrate 305.
[0034] A food grade substrate is used as a carrier for an edible,
decorative image that will be applied to the three-dimensional
comestible. In one implementation, the substrate is a thermoplastic
sheet made of, for example, virgin grade polyvinyl chloride,
polypropylene, polycarbonate, acrylic or high impact polystyrene.
The carrier may be transparent or opaque, although transparency can
assist certain steps in the process as noted below. In one
implementation, the carrier has a thickness in the range of
approximately 100-400 microns, and can be, for example, 275 microns
thick.
[0035] A mirror image outline of the original 2D artwork 200 is
printed onto the carrier (step 116). In one implementation, the
original 2D artwork 200 is used to create a screen of the mirror
image outline and the mirror image outline is screen printed onto
the carrier. Referring to FIG. 4A, the carrier 400 is shown
positioned within a screen printing machine 405. The carrier 400
can be aligned to a lay edge 410 (i.e., a guide) along a width-wise
side 411 of the carrier 400 and a second lay edge 415 along a
length-wise side 414 of the carrier. The lay edges 410, 415 can be
flat steel plates to guide or stop a sheet of material at
substantially the same place each time a sheet is positioned within
the machine. The mirror image screen is then used with the screen
printing machine 405 to print the mirror image outline 420 onto the
carrier 400, as depicted in FIG. 4B.
[0036] In one implementation, the blank carrier 400 can be aligned
within the screen printing machine 405 as follows, such that the
mirror image outline is printed at the appropriate location on the
carrier 400 so when the printed carrier 400 is placed within a
vacuum forming machine, the mirror image outline generally aligns
with the permanent model 310 (although other techniques to ensure
alignment can be used). Using a transparent carrier 400, an
operator places the blank carrier 400 face down over the permanent
model 310 affixed to the plate 305 and hand marks registration
points onto the backside of the blank carrier 400. For example, the
operator can trace an outline of the permanent model 310 or trace
certain features (e.g., the eyes and mouth of the Cartoon Man) onto
the carrier 400 using a felt tip pen (the tracings being the
registration points). When the carrier 400 is then placed (face-up)
within the screen printing machine 405 and the screen of the mirror
image outline is positioned over the carrier 400, the position of
the carrier 400 can be adjusted until the mirror image outline on
the screen is aligned to the registration points. That is, when the
carrier 400 is aligned to the screen, the registration points
marked onto the transparent carrier 400 will be visible to an
operator through the mirror image outline on the screen. The mirror
image outline will thereby be printed in the appropriate region on
the carrier 400, such that when the printed carrier 400 is placed
within the vacuum forming machine within the lay edges (described
below), the permanent model 310 will contact the printed carrier
400 at a location coinciding with the mirror image outline 420.
[0037] Referring to FIG. 5 and again to FIG. 1B, the printed
carrier 400 is positioned face down (i.e., printed side down) in a
vacuum forming machine 500 (step 118). The printed carrier 400 is
aligned to a lay edge 505 along a width-wise side of the carrier
400 and to a second lay edge 510 along a length-wise side of the
carrier. The printed carrier 400 can be warmed to increase
pliability, for example, to a temperature in the range of
approximately 60 to 80 degrees Celsius, such as 75 degrees Celsius
if using a polyvinyl chloride material to form the carrier 400. A
tray (not shown) upon which the plate 305 and permanent model 310
are positioned is raised up to meet the printed carrier 400 and a
vacuum is applied to deform the printed carrier 400 to the
permanent model 310 (step 120). The carrier 400 once separated from
the permanent model 310 is impressed with the 3D representation of
the decorative image, as shown in FIGS. 6A and 6B, and thereby
forms a 3D relief mold 600.
[0038] One example of a vacuum forming machine is a vacuum forming
unit available from Illig UK Ltd. of Bedfordshire, United Kingdom.
The mold tool (i.e., the plate 305 with the permanent model 310
affixed), in male or female format, used in the vacuum forming
machine can be made from aluminum, aluminum resin, brass, copper or
magnesium and can be coated with a heat resistant, non-stick
material, such as TEFLON.TM., Xylan or the like.
[0039] Referring to FIG. 6A and again to FIG. 1B, the mirror image
outline 620 of the original 2D artwork 200 that was printed onto
the carrier 400 is deformed during the vacuum forming process, by
virtue of the carrier being stretched to form a 3D relief mold. The
deformed outline 620 is examined to determine whether the outline
aligns with the 3D impression 600 of the decorative image now
formed in the carrier (step 122). If the deformed outline 620 does
not align with the 3D impression 600 ("No" branch of step 122),
then the amount by which the outline should be moved when printed
onto the carrier before deformation--so that upon deformation the
outline will align with the 3D impression 600--is measured (step
124). Deformation generally occurs due to the height or depth of
the 3D impression.
[0040] In FIG. 6A the mirror image outline 620, which is shown as a
solid line, and the boundary of the 3D impression 600, which is
shown as a dotted line, appear to align in some regions and are not
aligned in others. For example, at the top of the Cartoon Man's
head, the outline 620 is a distance x from the boundary of the 3D
impression 600 corresponding to the top of the Cartoon Man's head.
Distances of misalignment, such as distance x, are measured where
the outline 620 does not align to a corresponding feature formed in
or by the 3D impression 600.
[0041] An example of a disproportionate 2D artwork 700 is shown in
FIG. 7A, and is shown overlaying the original 2D artwork 200
represented as a dotted line in FIG. 7B, to illustrate the
adjustments made to the original 2D artwork 200. For example, the
girth in the stomach region 710 of the Cartoon Man results in more
deformation in the stomach region 710 than in less protruding areas
of the Cartoon Man, such as the hands 720. Accordingly, the
deformed outline is less likely to align to the 3D impression in
the stomach region 710 due to the outlining deforming considerably
in this region.
[0042] Referring again to FIG. 2, the original 2D artwork 200 is
adjusted based on the measurements to create an adjusted 2D artwork
(step 126). For example, the Cartoon Man's head can be adjusted
based on the measurement of the distance x between the outline 620
and the 3D impression 600. The adjusted 2D artwork is
disproportionate to the original 2D artwork 200, so that when an
outline based on the adjusted 2D artwork is applied to the carrier
and deformed to create a 3D relief mold, the outline aligns with
the 3D impression formed in the carrier (i.e., the 3D relief mold).
That is, for example, at the top of the Cartoon Man's head the
printed outline based on the adjusted 2D artwork will align with
the boundary of the 3D impression, as compared to the obvious
misalignment depicted in FIG. 6A. Typically, one or more additional
iterations of the process described above, in particular steps
116-126 are required to finally adjust the original 2D artwork 200
such that when deformed, the decorative image aligns to the 3D
relief mold.
[0043] For example, the adjusted 2D artwork created at step 126 is
used to create a mirror image outline of the adjusted 2D artwork
that is then printed onto a blank carrier (2.sup.nd iteration of
step 116). The printed carrier is positioned face down in a vacuum
forming machine (2.sup.nd iteration of step 118) and is vacuum
formed to the permanent model (2.sup.nd iteration of step 120). An
operator then examines the deformed adjusted outline to determine
whether or not the outline aligns with the 3D impression formed in
the carrier (2.sup.nd iteration of step 122). If the deformed
outline still does not align to the 3D impression ("No" branch of
decision step 122), then the operator measures the movement of the
adjusted outline with respect to the 3D impression (2.sup.nd
iteration of step 124) and adjusts the artwork a second time based
on the measurements (2.sup.nd iteration of step 126).
[0044] If the deformed outline does align to the 3D impression
("Yes" branch of decision step 122), then the adjusted artwork that
was used to create the deformed outline has been adjusted
sufficiently from the original 2D artwork 200, such that when
deformed the decorative image aligns to the 3D relief mold.
Referring to FIG. 1C, the adjusted artwork is used to print a
corresponding colored decorative image onto a carrier (step 130).
For example, if a screen printing process is used to print onto the
carrier, then a multi-step process may be used to print the color
image, for example, if multiple colors are required to create the
colored image.
[0045] FIG. 8 shows the Cartoon Man 800 printed in color on a
carrier 805. The targets 810 shown in the corners of the carrier
805 can be used to align the screens used in a multi-step process
to the carrier 805, such that the colored image printed onto the
carrier 805 with respect to each screen is in alignment.
Alternative methods of printing can be used, such as offset
printing, thermal transfer, ink jetting, and the like. The colored
decorative image can be printed using an edible ink composition,
such as the composition described below.
[0046] The color printed carrier 805 is vacuum formed to the
permanent model 310 (step 132), thereby creating a 3D relief mold
with the colored decorative image 800 adhered to the mold surface.
If a male mold tool is used, such as the permanent model described
in the illustrative example above, then the colored image is
adhered to an interior surface of the mold. Alternatively, a female
(i.e., concave) mold tool can be used, in which case the colored
image is adhered to an exterior surface of the mold. The color is
applied using an edible ink mixture, described further below.
[0047] The relief mold can either be filled with an edible material
(step 134), for example, a jelly, fudge, gelatinous edible
composition (e.g., nougat, gummi), chocolate or a chocolate
compound, or the relief mold can be stored for later use. To fill
the relief mold with an edible material, the carrier 805 is
trimmed, if necessary, to fit within a filling machine. Suitable
machines are available from Knobel in Switzerland. A jelly, fudge,
chocolate or chocolate compound can be melted and deposited into
the relief mold. For example, chocolate can be melted to a
temperature of approximately 35-50.degree. Celsius. The filled
relief mold can be cooled, for example, by passing the filled
relief mold through a cooling tunnel. Suitable cooling tunnels are
available from Sollich of Peterborough, United Kingdom. In one
implementation, a relief mold filled with chocolate or a chocolate
compound is cooled to 5.degree. C. for approximately 15 minutes. In
another implementation, a relief mold filled with a gelatinous
edible composition is cooled to 5.degree. C. for approximately 15
minutes, e.g., to result in the formation of a "skin" on the
gelatinous edible composition. Once the edible material has cooled
to a temperature at which the edible material is self-supporting,
the edible material is removed from the mold (step 136) with the
color image adhering to a surface of the edible material.
[0048] In embodiments where a gelatinous edible composition is
deposited, the gelatinous edible composition deposited may be first
cooled to "skin" the composition as described above, then cooled
for an additional period of time, e.g., in a refrigerator, before
being conditioned, e.g., at room temperature, as described
below.
[0049] The demolded comestible product may be an edible chocolate
or gelatinous figurine, which may be used as a cake adornment, for
example. FIG. 9 shows a finished 3D comestible product 900 with the
Cartoon Man decorative image applied to a non-planar surface of the
product 900, which product 900 is used to adorn the top of a cake
905.
[0050] Once a suitably adjusted 2D artwork has been arrived at
using the techniques described above in reference to FIG. 1B,
multiple relief molds can be produced at the same time for mass
producing the desired comestible product. Multiple decorative
images can be applied to a single carrier, and a corresponding
number of multiple permanent models affixed to a single substrate.
The carrier can then be vacuum formed to the substrate, thereby
forming multiple relief molds from the carrier. The carrier can be
cut to separate the multiple relief molds.
[0051] In one implementation, an empty relief mold can be stored
for at least six months before being filled with an edible
material. An empty relief mold can be stored at ambient temperature
in a sealed bag or other such packaging providing a good moisture
vapor barrier. The edible material can be stored in the mold for at
least 18 months before being demolded. A filled mold can be stored
in chilled conditions, for example, at a temperature of
approximately 0 to 10.degree. C., to maintain freshness.
[0052] Exemplary packaging materials for packaging an empty or
filled mold can include polypropylene films, polyester films such
as MYLAR.RTM. (available from E.I. du Pont de Nemours and Company
of Wilmington, Del.), foils (e.g., aluminum) and the like, and may
be packed in a sturdy corrugated box to prevent damage.
[0053] In one implementation, a comestible product may be formed
from two or more different portions. For example, referring to the
Cartoon Man cake adornment 900 shown in FIG. 9, in the process
described above, the Cartoon Man cake adornment 900 was formed from
a single relief mold as a one-piece comestible product. However, in
an alternative embodiment, the Cartoon Man cake adornment 900 can
be formed from multiple pieces, such as a separate piece for the
head, separate pieces for the arms and separate pieces for the
legs. That is, five separate comestible products can be formed and
then assembled together on top of the cake 905 to form the Cartoon
Man cake adornment 900. Each separate comestible product is formed
separately using the techniques described above in reference to the
Cartoon Man (as a whole). This multi-step process can be preferred
when creating fragile comestible products that may break, for
example, at points of weakness, such as where the arm attaches to
the body, or the like.
[0054] Gelatinous Edible Compositions
[0055] Gelatinous edible compositions and methods for making the
same are provided herein. A gelatinous edible composition can be
used in the processes described herein to result in printed
gelatinous edible compositions. Examples of gelatinous edible
compositions include nougats and gummis.
[0056] A gummi-type gelatinous edible composition can include one
or more of each of the following: a sweetener, a gelling agent, a
preservative, a flavorant, and a colorant. In certain cases, a
gummi-type gelatinous edible composition can further include a
shortening agent. Typically, a gummi-type gelatinous edible
composition also includes water, and can be prepared as an aqueous
mixture or solution at a higher temperature (e.g., from about
90.degree. C. to about 120.degree. C.), which subsequently gels at
reduced temperatures (e.g., below about 60.degree. C.). Depending
on the gummi-type composition, water can be included from about 10%
to about 35% by weight of the final composition, e.g., from about
11% to about 15%, from about 20% to about 25%, from about 30% to
about 35%, or at about 12.7% or 23%. As used herein, a "final"
gelatinous edible composition is the composition that is deposited
into a relief mold prior to gelling and/or setting and
conditioning.
[0057] For a gummi-type gelatinous edible composition, one or more
sweeteners can be included at a percentage by weight of the final
composition of about 30% to about 75%, or any value or range
therebetween (e.g., about 30% to about 45%; about 40% to about 70%;
about 50% to about 68%, or about 60% to about 70%). A sweetener can
be selected from the following: cane sugar, granulated sugar, a
sugar syrup (e.g., corn syrup, glucose syrup, or fructose syrup),
or a low calorie syrup (e.g., sorbitol, maltitol, xylitol, or
lactitol). In certain cases, one or more sweeteners for use in a
gummi-type gelatinous edible composition can include a sugar syrup
or a low calorie syrup and granulated sugar. In such cases water
may be included, e.g., to aid in dissolution of the granulated
sugar. In other cases, only sugar syrups and/or low calorie syrups
are used, with a reduced amount or no water required. In yet other
cases, a sugar syrup, a low calorie syrup, a granulated sugar, and
water can be used. In certain cases, one or more sweeteners can be
blended to form a sweetener solution (e.g., with water if included)
and then heated (e.g., to a temperature from about 110.degree. C.
to about 120.degree. C., such as 116.degree. C.), followed by
cooling to about 90.degree. C. to about 100.degree. C. prior to the
addition of a gelling agent.
[0058] A gelling agent for use in a gummi-type gelatinous edible
composition functions to provide elasticity and chewiness. Gelling
agents can be selected from fish, bovine, and poultry gelatin.
Typically a gelling agent is included in an amount of from about 3%
to about 10% by weight of the final gelatinous edible composition,
or any value therebetween, e.g., about 4%, 4.5%, 5%, 5.5%, 6%,
6.5%, 7%, 7.1%, 7.2%, 7.3%, 7.4%, 7.5%, 8%, 8.5%, 9%, and 9.5%. In
the preparation of gummi-type gelatinous edible compositions, a
gelling agent is typically dissolved, e.g., in hot water such as
water having a temperature from about 65.degree. C. to about
85.degree. C. (e.g., 77.degree. C.). The aqueous gelling agent
solution can then be added to a sweetener solution, e.g., as
prepared above and at a temperature of about 90.degree. C. to about
100.degree. C. In certain cases one or more sweeteners can be added
to a gelling agent solution prior to mixing of the gelling agent
solution with the sweetener solution described previously.
[0059] A shortening agent can be included in a gummi-type
gelatinous composition in a concentration by weight percent of from
about 0% to about 5%, e.g., 0.5%, 1%, 1.5%, 2%, 2.5%, 3%, 3.5%, 4%,
or 4.5%. A shortening agent serves to lend a slightly easier bite
to the final gelatinous edible composition. Useful shortening
agents include a unrefined or refined, modified or unmodified
starch, such as a wheat starch, maize starch, potato starch, and
tapioca starch. A gum, such as pectin, agar, and carrageenan may
also be used. A shortening agent can be included in a sweetener
solution prior to heating the sweetener solution as described
above.
[0060] One or more food grade preservatives, colorants, and
flavorants can also be included in a gummi-type gelatinous edible
composition. A preservative can be, for example, any food grade
preservative known to those having ordinary skill in the art, such
as citric acid monohydrate, and can be included in an amount of
from about 0.1% to about 3%, e.g., about 0.5%, 1%, 1.5%, 1.6%,
1.7%, 1.8%, 1.9%, 2%, 2.5%, and 2.8%. As used herein, colorants
include color enhancing agents and whitening or opacifying agents.
Suitable colorants can be, for example, whiteners, colorants, inks,
dyes, or pigments. Any known colorant approved for human
consumption can be used, including, for example, carmoisine,
quinoline, ponceau 4R, blue 1, vegetable carbon, blue V, blue 2,
and FD&C pigments such as yellow 5, red 3, red 40, blue 1, and
blue 2. Additional useful examples include powdered inks, e.g.,
E100, E102, E104, E110, E120, E122, E124, E127, E129, E131, E132,
E133, E140, E141, E153, 160, E161(1), E163, E170, and E171.
Typically, a food grade colorant for use herein is soluble in
aqueous solutions. A colorant typically is added in an amount
quantum satis, or an amount necessary to achieve the desired color
and intensity required. Flavorants can also be included if desired
and in amounts quantum satis.
[0061] To prepare a gummi-type gelatinous edible composition, e.g.,
for deposition into a printed relief mold and subsequent removal,
the following process can be used:
[0062] 1. Hydrate the gelling agent (e.g., gelatin) in hot water
(e.g., at a temperature of from about 65.degree. C. to about
85.degree. C., such as 77.degree. C.) to form a gelling agent
solution. It should be mixed and allowed to stand until clear. Skim
foam off after standing. If desired, blend low calorie syrup (e.g.,
sorbitol) into gelling agent solution.
[0063] 2. Combine one or more sweeteners, water (if included), and
shortening agent (if included) to form a sweetener solution and
heat, e.g., at a temperature from about 110.degree. C. to about
120.degree. C., such as 116.degree. C. In certain cases, a
sweetener solution may include from 86-87% total solids. Cool to
about 90.degree. C. to about 100.degree. C.
[0064] 3. Add the gelling agent solution to the sweetener solution.
Blend slowly or use a vacuum blender to prevent air incorporation.
Ensure that gelling solution is completely dissolved.
[0065] 4. Add any preservative, flavorants, or colorants to the
above mixture to form the final gelatinous edible composition.
[0066] 5. Deposit within about 30 minutes, e.g., into printed
relief molds. Depositing of the gelatinous edible composition in
the relief mold can occur at a temperature of from about 40.degree.
C. to about 80.degree. C., or from about 50.degree. C. to about
75.degree. C., or from about 60.degree. C. to about 70.degree. C.
Note that an agitated and heated holding vessel may be required
here to hold the product prior to depositing if a continuous
process is required.
[0067] 6. Expose the deposited gelatinous edible composition to a
temperature of from about 4.degree. C. to about 10.degree. C. (e.g.
about 5.degree. C.) for a period of about 5 to about 50 minutes,
e.g., about 5 to about 20 minutes, about 10 to about 20 minutes,
about 20 to about 40 minutes, about 10 to about 30 minutes, in
order to form a skin on the deposited gelatinous edible
composition. The exposing can occur in a cooling tunnel.
[0068] 7. Allow the deposited gelatinous edible composition to set
for a period of about 1 to about 5 hours at a temperature of from
about 1.degree. C. to about 5.degree. C. Setting can take place in
a refrigerator or cooling room. In certain cases, the time period
can be from about 2 to about 4 hours.
[0069] 8. Condition the deposited gelatinous edible composition in
the relief mold, e.g., at a temperature of from about 19.degree. C.
to about 24.degree. C., or from about 20.degree. C. to about
22.degree. C. Conditioning can occur for a period of from about 14
to about 75 hours, e.g., from about 18 to about 24 hours, or from
about 20 to about 72 hours. The conditioned deposited gelatinous
edible composition can then be removed from the mold, to yield the
decorated gelatinous edible composition.
[0070] Note that a conditioned gummi-type gelatinous edible
composition can, in certain cases, exhibit a moisture content of
from about 15% to about 22%, or from about 17% to about 20%.
[0071] A nougat-type gelatinous edible composition can include one
or more of each of the following: a sweetener, an aerating agent, a
preservative, a flavorant, and a colorant. Typically, a nougat-type
gelatinous edible composition also includes water, and can be
prepared as an aqueous mixture or solution at a higher temperature
(e.g., from about 90.degree. C. to about 140.degree. C.), which
subsequently gels at reduced temperatures (e.g., below about
60.degree. C.). Depending on the nougat-type composition, water can
be included from about 4% to about 35% by weight of the final
composition, e.g., from about 4% to about 6%, from about 11% to
about 15%, from about 20% to about 25%, from about 30% to about
35%, or at about 5.5%.
[0072] For a nougat-type gelatinous edible composition, one or more
sweeteners can be included at a percentage by weight of the final
composition of about 60% to about 95%, or any value or range
therebetween (e.g., about 60% to about 70%, about 75% to about 87%,
about 80% to about 90%, about 83% to about 88%). A sweetener can be
selected from the following: cane sugar, granulated sugar, icing
sugar, a sugar syrup (e.g., corn syrup, glucose syrup, or fructose
syrup), or a low calorie syrup (e.g., sorbitol, maltitol, xylitol,
or lactitol). In certain cases, one or more sweeteners can include
a sugar syrup or a low calorie syrup and granulated sugar. In such
cases water may be included, e.g., to aid in dissolution of the
granulated sugar. In other cases, only sugar syrups and/or low
calorie syrups are used, with a reduced amount or no water
required. In yet other cases, a sugar syrup, a low calorie syrup, a
granulated sugar, and water can be used. In certain cases, one or
more sweeteners can be blended to form a sweetener solution (e.g.,
with water if included) and then heated (e.g., to a temperature
from about 125.degree. C. to about 140.degree. C., such as from
about 120.degree. C. to about 127.degree. C., or from about
135-137.degree. C.).
[0073] One or more aerating agents can also be included in a
nougat-type gelatinous edible composition, at a percentage from
about 0.05% to about 1.5% by weight, e.g., 0.1%, 0.2%, 0.25%, 0.3%,
0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.1%, 1.2%, 1.3%, or
1.4%. An aerating agent can be a gluten, such as a hydrolysed
gluten, e.g., hydrolysed wheat gluten. Hyfoama 66 can be used as an
aerating agent and is available commercially from Food Ingredient
Technology, Ltd. An aerating agent can be mixed with one or more
sweeteners and beaten to form a stiff foam, e.g., with a high-speed
wisk or paddle. The heated sweetener solution described previously
can be added to this stiff foam. If needed, additional sweeteners
can also be incorporated into this final mixture.
[0074] One or more food grade preservatives, colorants, and
flavorants can also be included in a nougat-type gelatinous edible
composition, e.g., as described previously.
[0075] To prepare a nougat-type gelatinous edible composition,
e.g., for deposition into a printed relief mold, the following
process can be used:
[0076] 1. Mix one or more aerating agents with one or more
sweeteners to a stiff foam.
[0077] 2. Heat one or more sweeteners to 125.degree. C. to about
140.degree. C., such as from about 120.degree. C. to about
127.degree. C., or from about 135-137.degree. C. This step might
require specialized equipment such as a sugar boiler with a low
speed mixing option. Add to the stiff foam of step 1.
[0078] 3. Add one or more sweeteners, if desired, to the mixture of
step 2. Do not over-mix.
[0079] 4. Add any preservative, flavorants, or colorants to the
above mixture to form the final gelatinous edible composition.
[0080] 5. Deposit within about 30 minutes, e.g., into printed
relief molds. Depositing of the gelatinous edible composition in
the relief mold can occur at a temperature of from about 40.degree.
C. to about 80.degree. C., or from about 50.degree. C. to about
75.degree. C., or from about 60.degree. C. to about 70.degree. C.
Note that an agitated and heated holding vessel may be required
here to hold the product prior to depositing if a continuous
process is required. In addition, specialized depositing equipment
may also be required, such as heated lines to deal with the high
viscosity of the solutions.
[0081] 6. Expose the deposited gelatinous edible composition to a
temperature of from about 4.degree. C. to about 10.degree. C. (e.g.
about 5.degree. C.) for a period of about 5 to about 50 minutes,
e.g., about 5 to about 20 minutes, about 10 to about 20 minutes,
about 20 to about 40 minutes, about 10 to about 30 minutes, in
order to form a skin on the deposited gelatinous edible
composition. The exposing can occur in a cooling tunnel.
[0082] 7. Allow the deposited gelatinous edible composition to set
for a period of about 1 to about 5 hours at a temperature of from
about 1.degree. C. to about 5.degree. C. Setting can take place in
a refrigerator or cooling room. In certain cases, the time period
can be from about 2 to about 4 hours.
[0083] 8. Condition the deposited gelatinous edible composition in
the relief mold, e.g., at a temperature of from about 19.degree. C.
to about 24.degree. C., or from about 20.degree. C. to about
22.degree. C. Conditioning can occur for a period of from about 14
to about 75 hours, e.g., from about 18 to about 24 hours, or from
about 20 to about 72 hours, or from about 24 to about 48 hours. The
conditioned gelatinous edible composition can then be removed from
the relief mold, e.g., to yield the decorated gelatinous edible
composition.
[0084] For both gummi- and nougat-type gelatinous edible
compositions, the interior surface of the relief mold may in
certain cases be fully printed, e.g., in order to ensure that the
gelatinous edible composition does not stick to the mold.
[0085] Edible Ink Compositions
[0086] Edible ink compositions described herein can be screen
printed in a four-color process, for example, and are easily
transferable from formed plastic molds and carriers to a comestible
product. An edible ink composition can include one or more of each
of the following: a viscosity controller, a film forming compound;
an emulsifier; and a food grade colorant. Optional ingredients can
include one or more plasticizers or humectants. For application to
a carrier, an edible ink composition is typically prepared as an
aqueous solution.
[0087] Viscosity Controllers
[0088] One or more viscosity controllers can be used to provide
structure and viscosity to an edible ink composition, e.g., to
facilitate application to a carrier. Examples include various food
grade starches and sweeteners. Starches in unrefined, refined,
unmodified or modified form can be used. Exemplary starches include
maize (corn), potato, wheat, and tapioca starch. Exemplary
sweeteners include glucose, lactose, dextrose, fondant icing sugar,
and icing sugar.
[0089] The total amount of viscosity controllers can range from
about 65% to about 80% by weight of an aqueous edible ink
composition, or any value therebetween (e.g., 66, 67, 68, 69, 70,
71, 72, 73, 74, 75, 76, 77, 78, 79% by weight). In some
embodiments, the total amount of viscosity controllers can range
from about 70% to about 75% by weight of an aqueous edible ink
composition, or any value therebetween. In certain embodiments, the
total amount of viscosity controllers will range from about 72% to
about 74% by weight of an aqueous edible ink composition. For
example, fondant icing sugar can be used at about 73% by
weight.
[0090] Starches and sweeteners for use as viscosity controllers can
be purchased commercially from a variety of sources, e.g., Penford
Foods, Englewood Colo.
[0091] Film Forming Compounds, Plasticizers, and Humectants
[0092] One or more film forming compounds can be used to provide
bendability, flexibility, and peelability to an edible ink
composition, e.g., to facilitate its removal from a carrier and
transfer to a comestible product. Exemplary film forming compounds
include hydroxypropylmethylcellulose and methylcellulose. Gum
compounds can also be used as film forming compounds. For example,
guar, acacia, or arabic gums can be used as a film forming
compound.
[0093] One or more film forming compounds can be included in an
amount ranging from about 0.6% to about 4% by weight of an aqueous
edible ink composition, or any value therebetween (e.g., 0.8%,
0.9%, 1.0%, 1.2%, 1.4%, 1.6%, 1.8%, 2%, 2.2%, 2.4%, 2.6%, 2.8%, 3%,
3.2%, 3.4%, 3.6%, or 3.8%). In some embodiments, one or more film
forming compounds can be included in an amount ranging from about
0.8% to about 1.4% by weight of an aqueous edible ink composition,
or any value therebetween (e.g., 0.9%, 1%, 1.1%, 1.2%, or 1.3%).
For example, hydroxypropylmethylcellulose can be included in an
amount of about 0.8% by weight.
[0094] In some embodiments, one or more plasticizers and/or
humectants are also included in an aqueous edible ink composition.
Plasticizers and/or humectants can be used to retain moisture and
impart flexibility. One or more humectants or plasticizers, or
both, can be included in a total amount from about 0.03% to about
0.4% by weight of an aqueous edible ink composition, or any value
therebetween (e.g., 0.04, 0.05, 0.06, 0.07, 0.08, 0.1, 0.12, 0.15,
0.18, 0.2, 0.22, 0.25, 0.28, 0.3, 0.32, 0.35, 0.38%). A typical
plasticizer for use in a composition described herein is propylene
glycol; a typical humectant is glycerine. For example, in some
embodiments, propylene glycol is included in an amount of about
0.06% by weight of an aqueous edible ink composition.
[0095] Emulsifiers
[0096] An edible ink composition can include one or more
emulsifers. An emulsifier can help to ensure homogeneity of an
edible ink composition and to maintain the clarity of an image
applied to a comestible. Suitable emulsifiers include, for example,
lecithin, polyglycerol polyricinoleate, acetic esters of
monoglycerides, polyoxyethylene sorbitan monostearate (e.g. a
commercially available product known as POLYSORBATE 60, CRILLET,
CRILLET VEG A, TWEEN, or TWEEN 60), and combinations thereof.
[0097] The choice of emulsifier can be influenced by the nature of
the comestible to which the colored decoration is to be applied.
For example, for chocolate comestibles, lecithin may be useful,
while POLYSORBATE 60 may be used for sugar-based confections, such
as hard candies or fudge. In other embodiments, a mixture of
emulsifiers can be used. A useful emulsifier mixture can include
lecithin and POLYSORBATE 60.
[0098] The total amount of emulsifiers in an aqueous edible ink
composition can range from about 1% by weight to about 12% by
weight, or any value therebetween (e.g., 1.2, 1.5, 2, 2.2, 2.5,
2.6, 2.8, 2.9, 3, 3.2, 3.5, 3.8, 4, 4.2, 4.5, 4.8, 5, 5.2, 5.5,
5.8, 6, 6.2, 6.5, 6.8, 7, 7.2, 7.5, 7.8, 8, 8.2, 8.5, 8.8, 9, 9.2,
9.5, 9.8, 10, 10.2, 10.5, 10.8, 11, 11.2, 11.5, or 11.8%). For
example, a mixture of lecithin and POLYSORBATE 60 can be used,
where the lecithin ranges from about 3% to about 7% by weight of an
aqueous edible ink composition, and the POLYSORBATE 60 ranges from
about 0.5% to about 5% by weight of an aqueous edible ink
composition. In one embodiment, lecithin is used in an amount of
about 5.8% and POLYSORBATE 60 is used in an amount of about
2.9%.
[0099] Food Grade Colorant
[0100] An aqueous edible ink composition can include one or more
food grade colorants. As used herein, colorants include color
enhancing agents and whitening or opacifying agents. Suitable
colorants can be, for example, whiteners, colorants, inks, dyes, or
pigments. Any known colorant approved for human consumption can be
used, including, for example, carmoisine, quinoline, ponceau 4R,
blue 1, vegetable carbon, blue V, blue 2, and FD&C pigments
such as yellow 5, red 3, red 40, blue 1, and blue 2. Additional
useful examples include powdered inks, e.g., E100, E102, E104,
E110, E120, E122, E124, E127, E129, E131, E132, E133, E140, E141,
E153, 160, E161(b), E163, E170, and E171. Typically, a food grade
colorant for use herein is soluble in aqueous solutions.
[0101] A colorant, e.g., a powdered ink, is added in an amount
quantum satis, or an amount necessary to achieve the desired color
and intensity required for a particular colored decoration. For
example, a powdered ink may be used at a pigment level between 5%
and 30% of the powdered ink. Typically, a colorant such as a
powdered ink is added in an amount of about 0.01% to about 0.4% by
weight of an aqueous edible ink composition, or any value
therebetween (e.g., 0.02, 0.04, 0.06, 0.08, 0.1, 0.12, 0.14, 0.16,
0.18, 0.2, 0.22, 0.24, 0.26, 0.28, 0.3, 0.32, 0.34, 0.36, or
0.38%), although amounts outside these ranges can be used in
particular cases to achieve a desired color intensity.
[0102] Water
[0103] Water is typically included in an amount of from about 13%
to about 25% by weight of an aqueous edible ink composition, or any
value therebetween (e.g., about 14, 14.2, 14.5, 14.8, 15, 15.2,
15.5, 15.8, 16, 16.2, 16.5, 16.7, 16.8, 17, 17.2, 17.5, 17.8, 18,
18.2, 18.5, 18.8, 19, 19.2, 19.5, 19.8, 20, 20.2, 20.5, 20.8, 21,
21.2, 21.5, 21.8, 22, 22.2, 22.5, 22.8, 23, 23.2, 23.5, 23.8, or
24% by weight). Certain embodiments have about 13% to about 18%
water. For example, one embodiment includes about 16.77% water.
Once prepared, a colored aqueous edible ink composition can be used
to achieve a four color process set or block print set, as
described previously.
[0104] Exemplary Edible Ink Composition
[0105] Edible ink compositions are typically aqueous solutions and
can be prepared using the previously described components at the
previously indicated percentage by weight amounts. For example, a
useful edible ink composition can be an aqueous edible ink
composition comprising:
[0106] a) one or more viscosity controllers at about 73% to about
75% by weight of said aqueous edible ink composition;
[0107] b) one or more film forming compounds at about 0.5% to about
1.4% by weight of said aqueous edible ink composition;
[0108] c) one or more emulsifiers at about 5% to about 12% by
weight of said aqueous edible ink composition;
[0109] d) one or more plasticizers at about 0.03% to about 0.09% by
weight of said aqueous edible ink composition; and
[0110] e) water at about 12% to about 20% by weight of said aqueous
edible ink composition.
[0111] In certain embodiments, the one or more viscosity
controllers is fondant icing sugar; the one or more film forming
compounds is hydroxypropylmethylcellulose; the one or more
emulsifiers are lecithin and POLYSORBATE 60; and the one or more
plasticizers is propylene glycol. For example, in a specific
embodiment, an aqueous edible ink composition can be prepared with
the following ingredients (amounts by weight %):
TABLE-US-00001 % by Weight Dry Ingredients Fondant Icing (powdered)
sugar 73.341 Hydroxypropylmethylcellulose 0.8 Liquid Ingredients
POLYSORBATE 60 2.94 Propylene Glycol 0.06 Lecithin 5.88 Water
16.77
[0112] Methods for Preparing an Edible Ink Composition
[0113] An exemplary method for preparing an edible ink composition
can include dissolving or dispersing one or more film forming
compounds and optional plasticizers and/or humectants in water
using, for example, a high shear hand blender or Silverson
Homogeniser. The aqueous mixture of film forming compounds (with
optional plasticizers or humectants) is referred to as a membrane
mixture. One or more food grade colorants can then be added and
similarly dispersed in the aqueous membrane mixture. The viscosity
controller, e.g., fondant icing (powdered) sugar, is then mixed
with the membrane mixture in a similar manner. Finally, one or more
emulsifiers, e.g., lecithin and POLYSORBATE 60, are added and mixed
in using, e.g., a Silverson Homogeniser, until a smooth liquid
results.
[0114] In certain cases, the material used to fill the mold (e.g.,
chocolate or chocolate compound) can be prepared accordingly to
conventional techniques, and may include some or all of the
following ingredients:
[0115] a. icing or fondant icing (powdered) sugar;
[0116] b. lactose;
[0117] c. lecithin;
[0118] d. cocoa butter;
[0119] e. butterfat;
[0120] f. hydrogenated vegetable oil;
[0121] g. whey powders;
[0122] h. milk powders;
[0123] i. whole milk;
[0124] j. skim milk powder;
[0125] k. full cream milk;
[0126] l. gelatine;
[0127] m. citric acid;
[0128] n. starch/modified starch;
[0129] o. pectin; and/or
[0130] p. corn syrup
EXAMPLES
Example 1
Exemplary Gummi and Nougat Gelatinous Edible Compositions
Hard Short Nougat
Recipe
TABLE-US-00002 [0131] kg % by weight Part I Hyfoama 66 0.100 0.242
Water 1.500 3.628 Icing Sugar 2.500 6.046 Part II Sugar 13.500
32.648 Water 4.500 1.861 Glucose Syrup 17.500 42.322 Part III Icing
Sugar 1.750 4.232
[0132] The following batch process was used to prepare nougat-type
gelatinous edible compositions: [0133] 1. In part I, beat all the
ingredients to a stiff foam. Use a high-speed whisk or paddle.
[0134] 2. In part II boil the ingredients to 127.degree. C. [0135]
3. Add the icing sugar from part III and mix in. Do not over mix.
[0136] 4. Allow to cool to 60-70.degree. C., and deposit in fully
printed molds. [0137] 5. Pass molds through Solich cooling tunnel
(5.degree. C.) where it skins the gummi solution. Chill in fridge
(2 to 4 hours) to improve set. [0138] 6. The product should be
fully hardened within 2 days (e.g., 2 days of conditioning) for
extraction from the molds.
Gummi Compositions
[0139] The following 3 recipes were prepared:
Recipe 1:
TABLE-US-00003 [0140] % by weight kg Part 1 Water 6.446 5.586 Icing
Cane Sugar 28.850 25.000 Glucose Syrup 36.700 31.802 Part 2 Hot
water (77.degree. C.) 14.850 12.868 Gelatin (Fish Gelatin Bloom
7.425 6.434 375) Sorbitol 2.333 2.022 Part 3 Water 1.698 1.471
Citric Acid Monohydrate 1.698 1.471 100.000 86.654
Recipe 2:
TABLE-US-00004 [0141] % by kg weight Part 1 Glucose Syrup 50 69.930
Part 2 Hot water (77.degree. C.) 11.4 15.944 Gelatin (Fish Gelatin
Bloom 5.5 7.692 375) Sorbitol 2 2.797 Part 3 Water 1.3 1.818 Citric
Acid Monohydrate 1.3 1.818 71.5 100.000
Recipe 3:
TABLE-US-00005 [0142] % by weight kg Part 1 Water 6.982 5.586 Cane
Sugar 27.926 25.000 Corn Syrup 35.524 31.802 Wheat Starch 2.053
1.838 Part 2 Hot water (77.degree. C.) 14.374 12.868 Gelatin 7.187
6.434 Sorbitol 2.259 2.022 Part 3 Water 1.643 1.471 Citric Acid
Monohydrate 1.643 1.471 Flavouring 0.411 0.368
[0143] The following batch process was used to prepare gummi-type
gelatinous edible compositions using the recipes above: [0144] 1.
Hydrate gelatin in hot water (.about.77.degree. C.). It should be
mixed and allowed to stand until clear. Skim foam off after
standing. [0145] 2. Mix Part 1 ingredients and heat at 116.degree.
C. Cool to 100.degree. C. [0146] 3. Blend sorbitol into gelatin
solution. Add the gelatin solution to the Part 1 heated syrup.
Blend slowly or use a vacuum blender to prevent air incorporation.
Ensure gelatin is completely dissolved. [0147] 4. Add the citric
acid water solution and deposit the batch at 60-70.degree. C.
within 30 minutes. [0148] 5. Once deposited into fully printed
molds (i.e. the whole surface has to be covered in print to prevent
sticking to plastic), the gummi solution is passed through a Solich
cooling tunnel (5.degree. C.) where it skins the gummi solution.
[0149] 6. The molds are placed in the fridge (2 to 4 hours) to get
a proper set. Once cooled they should be placed in a conditioning
room. Industrially the target moisture is 17-20% (21.degree. C. air
temperature) and an average rate of setting time is 18 to 24 hours.
Results show that conditioning at room temperature for 2-3 days
gives the desired consistency, although this depends on atmospheric
conditions.
[0150] A number of embodiments of the invention have been
described. Nevertheless, it will be understood that various
modifications may be made without departing from the spirit and
scope of the invention. Accordingly, other embodiments are within
the scope of the following claims.
* * * * *